Electrical connector



April 24, 1945. v CARLSQN 2,374,413

ELECTRICAL CONNECTOR Filed Aug. 17, 1942 2 Sheets-Sheet 1 W "'H M WINVENTOR VERN E. R so ATT R April 24, 1945. v E, CARLSQN 2,374,413

ELECTRICAL CONNECTOR Filed Aug. 17, 1942 2 Sheets-Sheet 2 fullyunderstand Patented Apr. 24, 1945 FFlCE 2,314,413 nrncrnroancomoronVernon E. cumin, Short Hills, N. J., assignor to Elizabeth.

Aircraft-Marin e Products, Inc,

N. J., a corporation of New Jersey Application August 17, 1942, 'SerialNo. 455,032 3 Claims. (Cl. 173-269) This invention relates to electricalconnections and connectors; More particularly, the invention relates toconnectors in which one portion engages and contacts an electricalconductor while another portion holds an insulating cover 1 on saidconductor. Connectors of this general time have been commonly used onelectrical conductors for various purposes, particularly in wiring ofaeroplanes, automobiles, radios, etc.

The present invention is primarily concerned with connectors which arefabricated from sheet material, that. is, flat stock, whether so-calledstrip or sheets, and so constructed and arranged that they may bepermanently secured to electrical conductors in a simple manner andadvantageously. without the use of solder, and in which the conductorengaging portion and the insulation supporting portion are formed fromintegral parts of the same flat stock.

It is an object or the present invention to provide a connector for aninsulated electrical conductor which will effectively grip both theconductor itself and the insulation thereon when crimped or compressedafter application to the insulated conductor, and will make aperinanently good electrical contact therewith. Another object is theprovision of an electrical connector which will be relativelyinexpensive while at the same time giving maximum effectiveness forholding an electrical conductor. A still further object is the provisionof an improved, onepiece connector adapted to grip both the wire and theinsulation of an insulated electrical conductor. Further objects will bein part pointed out as the description proceeds and in part will becomeapparent therefrom. 1

In these drawings, I have shown and described a preferred embodiment ofmy invention and various modifications thereof; but it is to beunderstood that these are not intended to be exhaustive nor the contraryare given for purposes of illustration in order that others skilled inthe art may the invention and the principles thereof and the manner ofapplying it in practical use so that they may modify and adapt it invarious forms, each as maybe best suited to the conditions of aparticularsuse.

In the drawings, in which like reference characters refer to like'partsthroughout: 1

Figure 1 is a plan view of a, blank for a novel and improved connectorincorporating the invention;

been formed and applied to the endof an electrical conductor;

Figure 3 is an'enlarged sectional view of the device of Figure 2 takenalong the line 3-3 of Figure 2 in the direction of the arrows;

Figure 4 is a plan view of a blank for another form of connector made inaccordance with theinvention;

. Figure 5 is an edge view of a connector formed from the blank'illustrated in Figure 4;

Figure 6 is a plan view of another-blank for a connector embodying myinvention;

limiting of the invention, but on Figure 2 is a plan view of theconnector. made I from the blank of Figure 1 shown after it has Figure 7is'an edge view of the formed from the blank of Figure 6;

connector Figure 8 is an edge view of the same connector' as shown inFigure 7 but taken at right angles to the view of Figure '7 and aftervthe connector has been applied andcrimped onto a conductor:

Figure 9 is a plan view of another blank for a modified form ofconnector;

Figure 10 is a view similar to that of Figure 2 showing a connectorformed from the blank of Figure 9;

Figure 11 is a plan view of a blank for another form of connector tion;

Figure 12 is a plan view of a connector formed from the blank shown inFigure 11;

Figure '13 is a plan view of still another blank for a connectorembodying the invention;

Figure 14 is an edge view showing how the blank of Figure 13 mayberolled to be applied to an insulated wire Figure 15 is a plan view ofanother blank for a connector embodying the invention;

Figure 16 illustrates the connector formed from the-blank of Figure 15ready to be applied to the end of an electrical conductor;

Figure 17 is a longitudinal sectional view of another embodiment of theinvention; and

Figure 18 is, a view similar to that of Figure 17 but showing theferrule after it has been folded and pressed onto the end of anelectrical conductor.

The blanks above illustrated may be stamped or cut from dead soft, orpartially hardened up to about quarter-hard, flat, good-conductingmetal, for example, malleable, pure sheet copper. The connectors of thepresent invention are designedior use with insulated wire, for example,the fine wire types found in aeroplane wiring, radios, etc., up to theheavy, types used for motors and generating equipment.

Figure 1 illustrates a blank 20 having itsmid-- vPortion adapted to forma terminal connecting embodyin the invenfolding.

As shown in Figure 2, the folding and punchin of the portion 2! and therolling up of the end portions 22 and 24 is complete and a conductorconsisting of insulation 25 and a copper wire 26 is inserted. The earsof end portion 22 have been wrapped around the insulation 25 and thetabs of end portion 24 have been rolled up to ferrule form and thencrimped onto the wire 26 at 21. The

crimping may be done by any suitable tool, for

. example, that shown in copending application of S. N. Buchanan, SerialNo. 421,408, filed December 3, 1941, which compacts the copper of theferrule and of the wire into a relatively solid mass (see Figure 3). Theears of end portion 22 are wrap ped tightly around the insulation 25 sothat a direct pull on the conductor is taken first by the insulation andonly later by the wire 26. The latter, moreover, being bent from itsposition in the portion 22 to its position in the ferrule 24, can nottransmit a direct, axial pull and, therefore, maintains the electricalcontact established by crimping.

The form of the end portions Hand 24 in Figures 1 and2 is not essentialto my invention. Any other integral connecting and embracing means maybe used, as illustrated, for example, by Figures 4 to 18.

Figure 4 depicts a blank 26aconsisting of a terminal portion 2la, likethat of Figure 1, and end portions 22a and 24a for rolling intotransverse ferrules for holding the insulation and wire, respectively,of an insulated conductor.

In Figure 4, both ends of the blank a are rolled up on the same side ofthe metal so that when the terminal portion 21a is folded, as shown inFigure 5, the end portions 22a and 26a are side by side. Thisarrangement is advantageous in that any pull on the wire is takenagainst the doubled portion 21a where it merges into the end portions22a and 24a without any possibility of pulling upon the rolled upferrules. It is not essential to this result, however, that the ferruleportions be rolled on the same side. Thus. if they are rolled onopposite sides of the sheet metal blank and then folded so that onecomes just beyond the other and side by side, substantially the sameresult will be attained. In either case the structure has the advantagethat both ferrules, lying side by side, may be crimped onto the wirewith the same tool in a single operation and that such crimping willtend to hold them solidly together.

Instead of using both rolled portions to hold one conductor, each may becrimped onto a separate conductor so that the ferrule serves to bringtwo conductors to a single binding post.

Although I have referred to the portions 22 and 24 which embrace andhold the wire and insulation as end portions, it is not essential thatthey should be located at oppositeends of the blank, as in Figures 1 and4. Instead, these end portions may be at a side edge of the blank onopposite sides of the fold line, as shown in Figure 6. or on adjacentedges, as shown in Figure ll. When the blank of Figure 6 is formed andapplied to a wire it has the advantage that the bared wire 26 passesover the folded edge of the metal, as shown in Figure 8, which affords asmooth snubbing surface to absorb a major part of any pull on the wirewith no tendency to cut or break it. The wire may be held in place bycrimping, as at 21b and 28b.

My invention, furthermore, is not limited to folding of the metal, as inthe examples of Figures 1 to 8 inclusive, but may likewise be embodiedin connectors of various forms with integral portions 22, 24 on the endsand /or sides of an unfolded portion which forms the terminal contactmember.

Thus, in Figures 9 and 10, a blank 20c is indicated having a terminalportion 210 and end portions 220 and 240. Figure 10 shows these endportions rolled to'ferrule form, 220 embracing the insulation 25 of theconductor and 240 embracing the wire 26 of the conductor. The ferruleportions are crimped, as indicated at 21c and 26a.

- The embodiment shown in Figures 11 and 12 is similar in structure andfunction except that the portions 220! and 24d, which form the ferrulesfor holding the wire 26 and the insulation 25, are, in this case, onadjacent sides instead of on opposite sides of the contact portion 2ld.

ure 12 illustrates how the conductor is held by the end portion 22d andthe side portion 24d. The rolled portions are crimped, as indicated at21d and 28d. to make a tight contact between the connector and theconductor, and a secure mechanical engagement.

In the embodiment shown in Figures 13 and 14, a blank 20c has a terminalportion 2 le at one side and end portions 22a and 24e substantiallytogether so that when rolled up the resulting ferrules will be side byside, as shown in Figure 14, with the resultant advantages discussed inconnection with the forms of Figures 4 and 6. Obviously, the terminalcontact portion 2le may be of any desired form, according to theterminal and conductor with which it is to make contact.

Although, as has been emphasized above, there is important advantage inthe side by side, or angular, arrangements of the ferrules 22, 24, otherfeatures of the structures shown may be used with advantage when axiallyaligned ferrules are desired. Figure 15 shows a blank 20f havingterminal portions 21) arranged to be folded together, as in the caseillustrated in Figures 1 through 3, and end portions 22) and 24f for theinsulation of the conductor and for the bared end of the wire,respectively. The blank is folded, as illustrated in Figure 16, to bringthe two ferrule portions into overlapping alignment and end portions 22)and 24! are rolled up to receive the conductor coaxially, asillustrated.

Figure 17 illustrates a connector which receives the electricalconductor between the overlapped contact portions 2lg and 249. Theinsulation 25 is received in the ferrule 229, the same as in theembodiments shown in the other figures. The upturned rim 30 around theopening 3| serves as a tubular rivet after the wire is in place and thepart, 2| 9 folded, as shown in Figure 18, and thus holds the foldedrelation and also holds the contact part 2lg tightly pressed in thechannel 249', which in this case serves as crimping onto a wire,

each conductor may be provided with separate of the rolled ferruleportions for the bare'd and wire and the insulated portion,respectively.

From the foregoing it will be seen that elec trical connections made inaccordance with the present invention are well adapted to attain the?ends and objects hereinbefore set forth and to each embe economicallymanufactured, since bodiment requires for its manufacture andapplication nothing more than conventional sheet material and formingtools. The rolled edge ferrule for application without as shown inFigures 4 to 14, is more particularly described and claimed in thecopending application, Serial No. 465,527;

filed November 14, 1942.

I claim:

solder by merely 1. An electrical connector of malleable: highconductivity metal fabricated from flat stock, said connector comprisinga flat terminal contact portion provided with an aperture, a pluralityof wire-receiving ferrules each formed of an integral edge portion ofsaid'stock rolled inwardly with its edge abutting said terminal contactportion for reception of a wire.

2. An electrical connector of malleable, high conductivity metalfabricated from flat stock, said connector comprising a flat terminalcontact portion formed by doubling the'stock back upon itself to form aflat area provided with an aperture, a plurality of wire-receivingferrules lying side-by-side and each being formed of integral edgeportions of the adjacent edges of the overlying stock rolled inwardlywith the edges abutting said terminal contact portion.

3. An electrical connector of malleable high conductivity metalfabricated from flat stock, said connector including tion and a pair ofwire receiving ferrules each formed of an integral edge portion of saidstock rolled inwardly with its edge abutting said terminal contactportion for receptionof a wire, said ferrules being arrangedsubstantially at right angles to each other.

VERNON E. CARI-SON.

a terminal contact por-'

